Method and apparatus for microwave reduction of organic  compounds

ABSTRACT

The invention described herein generally pertains to utilization of high power density microwave energy to reduce organic compounds to carbon and their constituents, primarily in a gaseous state. The process includes, but is not limited to, scrap tires, plastics, asphalt roofing shingles, computer waste, medical waste, municipal solid waste, construction waste, shale oil, and PCB/PAH/HCB-laden materials. The process includes the steps of feeding organic material into a microwave applicator and exposing the material to microwave energy fed from at least two linear polarized sources in non-parallel alignment to each other, and collecting the material. The at least two sources of microwave energy are from a bifurcated waveguide assembly, whose outputs are perpendicular to each other and fed through waveguide of proper impedance, such that the microwave sources are physically and electrically 90° out of phase to each other. The microwave frequency is between 894 and 1000 MHz, preferably approximately 915 MHz.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a continuation of U.S. patentapplication Ser. No. 11/670,041 filed 1 Feb. 2007, which claims priorityfrom U.S. Patent Application Ser. No. 60/825,002 filed 8 Sep. 2006 andU.S. Patent Application Ser. No. 60/766,644 filed on 2 Feb. 2006, bothprovisional applications hereinby incorporated by reference.

TECHNICAL FIELD

The invention described herein pertains generally to a method andapparatus for depropagating polymer-based materials, e.g., plastics,asphalt roofing shingles and rubber, including crosslinked plastics andrubber-based polymers, including cross-linked rubbers such assulfur-based crosslinks, as used in tires. A decrosslinked, and at leastpartially depolymerized product is achieved without combustion in asecond application, including computer waste and poly-chlorinatedbiphenyl (PCB), poly-aromatic hydrocarbon (PAH), and/or hexachlorinatedbenzene (HCB)-laden material. Organic material is dried, sterilized andvolumetrically reduced without an external heat source in a thirdapplication, including municipal solid waste (MSW), medical waste, andconstruction waste. Shale oil is driven from rock formations andrecovered in a fourth application. Bituminous coal is reduced to carbon,hydrocarbon gases and ash in a fifth application.

BACKGROUND OF THE INVENTION

In the field of petrochemicals, escalating energy costs for oil, naturalgas, liquefied petroleum gas (LPG), and liquefied natural gas (LNG) areof increasing concern to those involved in the processing of organicmaterials, chemicals, and petroleum products. With the inherent aging ofthe facilities, coupled with the ever-escalating energy and capitalequipment costs, refurbishment and replacement costs of these plantsbecomes increasingly difficult to justify. Many efforts have beenexpended in those applications described in the Technical Field toproduce directly useable fuels from scrap tires or plastics withoutfurther treatment, substantially improve throughput, increase operatingefficiency, or reduce energy consumption, but have failed due toeconomic or technical reasons. The present invention achieves all ofthese objectives through the direct application of high-densitymicrowave energy to various organic materials, while simplifying theprocess methods and apparatus. The uniqueness of the invention willbecome immediately apparent through the narrative presented in theDetailed Description of the Invention to those skilled in the art ofmicrowaves, petrochemical, and energy production processes.

SUMMARY OF THE INVENTION

In accordance with the present invention, in one aspect, there isprovided a microwave reduction process to more economically produce highquality syngas and liquid fuels, suitable for direct introduction intoan Internal Combustion Gas Turbine (ICGT), in the petrochemical,industrial, and energy markets within a specified and controlled rangeof Btu content, while operating below current emissions levels set forthby the U.S. Environmental Protection Agency (EPA). Alternately, theoutput heat from the ICGT may be passed through a heat exchanger in acombined cycle application for the production of electricity, steam, orother waste heat applications. The gas turbine is coupled to anelectrical generator to provide electricity for this invention. It isimportant to note that combustion of only the syngas fuel is sufficientto provide the total electrical requirements for the microwave systemand ancillary support equipment, plus excess energy is available forexport to the electrical grid. All of the recovered liquid fuel, carbonblack, and steel are available as a revenue stream to the customer. Forclarity and to dispel considerations of a perpetual motion device, itshould be noted that the heat potential of a scrap tire is approximately15,500 Btu/lb (36,053 kJ/kg). The recovered syngas containsapproximately 18,956 Btu/lb (LHV) (44,092 kJ/kg), the recovered fuel oilcontains approximately 18,424 Btu/lb (LHV) (42,854 kJ/kg), and therecovered carbon black contains approximately 14,100 Btu/lb (32,797kJ/kg). The typical amounts of recovered by-products through microwaveexcitation of scrap tires, based on a typical scrap tire mass of 20pounds (9.072 kg) is given in Table 1. It should be noted that operatingconditions, such as applied microwave power, applicator pressure,temperature and residence time will determine the gas:oil ratio derivedfrom the hydrocarbon gases identified in Table 1. Data relevant togas:oil data is presented in FIG. 8.

TABLE I Typical Scrap Tire Reduction By-Products from MicrowaveExcitation Hydrocarbon Gases: 11.8992 lbs.  (5.397 kg) 59.4958% Sulfuras H₂S: 0.0373 lbs. (0.017 kg) 0.1865% Chlorine as HCl: 0.0014 lbs.(0.001 kg) 0.0070% Bromine as HBr: 0.0125 lbs.  0.006 kg) 0.0627%Unspecified: Carbon Black: 4.8712 lbs. (2.209 kg) 24.3560% MetalOxides/Fillers: 0.8683 lbs. (0.394 kg) 4.3415% Plated High-Carbon Steel:2.3101 lbs. (1.048 kg) 11.5505% Total: 20.0000 lbs.  (9.072 kg)100.0000%

When the heat content of the various recovered by-products is consideredin conjunction with the mass percentages given in Table 1, an energybalance exists between the heat contained within the scrap tirefeedstock and the heat recovered from the microwave-reduced scrap tireby-products. A mass balance is also achieved between the tire feedstockand various recovered by-products.

High power density microwave energy has been utilized effectively toreduce polymers through molecular excitation of polar and non-polarmolecules, while producing intermolecular heating within low-lossdielectric materials.

These and other objects of this invention will be evident when viewed inlight of the drawings, detailed description and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangementsof parts, a preferred embodiment of which will be described in detail inthe specification and illustrated in the accompanying drawings whichform a part hereof, and wherein:

FIG. 1 is a top plan view of a microwave-based reduction system assemblydrawing illustrating microwave generators, applicator, chiller, scrubberand nitrogen generator set upon mobile trailers;

FIG. 2 is a side plan (elevation) view of the microwave applicatortrailer showing an infeed assembly, tractor-fed belt, cooling watertanks, diesel fuel day tank, and outfeed assembly;

FIG. 3 is a rear plan view of the assembly of FIG. 1;

FIG. 4 is an enlarged top view of a bifurcated waveguide assembly;

FIG. 5 is a side plan (elevation) view of the infeed assembly;

FIG. 6 is a side plan (elevation view) of the outfeed assembly;

FIG. 7 is a graph illustrating applied microwave power in kilowatts vs.throughput of scrap tires per day;

FIG. 8 is a graph illustrating by-products recovered from scrap tiresvs. applied microwave power in kilowatts;

FIG. 9 is a graph illustrating the thermal energy recovered from scraptire by-products, at an applied microwave power, as illustrated in FIG.7; and

FIG. 10 is a graph illustrating the equivalent electrical power producedfrom the thermal energy illustrated in FIG. 7 by an Internal CombustionGas Turbine (ICGT), operating in simple cycle mode, at a combustionefficiency of only 35%.

DETAILED DESCRIPTION OF THE INVENTION

The best mode for carrying out the invention will now be described forthe purposes of illustrating the best mode known to the applicant at thetime of the filing of this patent application. The examples and figuresare illustrative only and not meant to limit the invention, which ismeasured by the scope and spirit of the claims.

The scrap tire material received from the scrap tire processing plant istypically shredded in randomly sized pieces from ½ inch (12.7 mm)×½ inch(12.7 mm) to about 1 inch (25×4 mm)×1 inch (25.4 mm), usually containingall of the steel associated with the scrap tires. Some scrap tireshredders will remove about 60% of the steel, as part of the scrap tireprocessing for crumb rubber applications. This invention can processshredded scrap tire material with or without the steel Laboratory dataindicates that the overall microwave process efficiency increasesapproximately 10-12% with the reduced steel content in the scrap tirematerial, due to reduced reflected power, which is more than enough tooffset the cost of steel removal during the scrap tire shreddingoperation.

As illustrated in FIG. 1, the apparatus includes five (5) major elements(1) a mobile sealed microwave reduction multi-mode applicator 12,coupled to a mobile set of microwave generators 10, (2) a nitrogengenerator 11, which displaces any air within the microwave applicatorand provides a non-flammable blanketing gas over the organic materialunder reduction, in this case, scrap tire material, (3) gas processcondenser 13, which receives the hydrocarbon vapor stream from theoutput of microwave applicator, (4) a gas-contact, liquid scrubber 14,which removes 99.99% of the hydrogen sulfide, hydrogen chloride, andhydrogen bromide contaminants, (5) a air-water chiller 15, whichprovides continuous cooling water to the magnetrons and control cabinetsfor heat rejection, and (6) an electrical generator 17, sized to provideall electrical energy to the microwave system and ancillary equipment.

Within the mobile set of microwave generators 10, are illustrated five(5) individual microwave generators 18 in continuous electroniccommunication and controlled by a PLC in the main control panel 16. Eachmicrowave generator has a magnetron 20 and a microwave circulator 22with water load. The generated microwaves are coupled from eachmicrowave generator 18 to the microwave reduction applicator 12 viarectangular waveguides 26. In the particular microwave reduction systemshown in FIG. 1, an exhaust fan 40 is illustrated with associated motor42 to extract the hydrocarbon vapor from the applicator 12 and conveythe vapor stream to the process gas condenser 13.

Each waveguide assembly 31, which is illustrated in FIG. 4, contains abifurcated waveguide assembly 30, which directs the microwave energyinto specific microwave entry ports 36 in a direction collinear 32 withthe longitudinal plane of the applicator conveyor belt 19 and normal 34to this same longitudinal plane. Microwave leakage outside of the sealedapplicator is eliminated by an RF trap 38, consisting of an array ofchoke pins, designed to a length appropriate for the operatingfrequency.

As illustrated in FIG. 2, the microwave reduction applicator 12 has oneentry port 44 and one exit port 46, which are in longitudinalcommunication with a closed-mesh, continuous, stainless steel belt 19,said belt being of mesh composition, set within a pair of side guides,and having longitudinal raised sides for retention of the sample, saidsides being approximately 4 inches (10.16 cm) in elevation. Asillustrated, there are two access-viewing ports 48 positioned on eachside of the microwave reduction applicator 12. Illustrated in FIG. 1 andFIG. 2 are multiple microwave reduction applicators 12, which areinterconnected to form a continuous chamber 37. Each microwave reductionapplicator 12 consists of two (2) or four (4) waveguide 36 entry ports,depending on the specific application and the microwave power requiredfor the application. While a total of three (3) applicators 12 areshown, there is no need to limit the invention to such, as both largerand smaller numbers of applicators 12 necessary to arrive at anapplication-specific chamber 37 length, are envisioned to be within thescope of the invention. In fact, the invention works with only one (1)applicator chamber 37, with only 2 entry ports.

The microwave energy is coupled from the microwave generator 10 to theapplicator via a rectangular waveguide assembly 31 and exits the samethrough a bifurcated waveguide assembly 30. The source of the microwaveenergy is a magnetron, which operates at frequencies, which range from894 MHz to 2450 MHz, more preferably from 894 MHz to 1000 MHz, and mostprefereably at 915 MHz+/−10 MHz. The lower frequencies are preferredover the more common frequency of 2,450 MHz typically used inconventional microwave ovens due to increased individual magnetron powerand penetration depth into the organic material, along with an increasein operating efficiency from 60% in the case of 2450 MHz magnetrons, to92% for 915 MHz magnetrons. Each magnetron has a separate microwavegenerator control panel in electronic communication with a main controlpanel for system control.

As shown in FIG. 3, the microwave reduction applicator has an activearea, whose boundaries are set by the interior roof sheets 21 and thestainless steel belt 19. For the applicator described in this invention,the active microwave reduction chamber height is 24 inches (60.96 cm).It is well known how to appropriately size the active area of themicrowave chamber 37. The belt 19 traverses through the active areabetween two (2) continuous guides 21, whose open dimension is sufficientfor the belt 19 to pass, but is not a multiple or sub-multiple of themicrowave frequency. The height of the guides 21 is a nominal 4″ (10.16cm), which will contain the material on the belt 19. The closed-gridbelt provides the lower reference, which becomes the bottom of theactive area of the applicator.

In the event that the microwave energy is not absorbed by the organicmaterial, a condition, which results in reflected microwave energy, thisenergy is redirected by a device known as a circulator 20 andsubsequently absorbed by a water load 22. The circulator is sized toabsorb 100% of the microwave energy generated by the magnetron. Eachmagnetron transmits its energy via a waveguide 24 through a quartzpressure window assembly 23, into the series-connected microwavereduction chamber(s). The quartz pressure window assembly 23 includestwo flanges separated with rectangular waveguide, one (1) wavelengthlong, each flange containing a milled recess to accept ¼ thick fusedquartz window, which is microwave-transparent. The quartz pressurewindow assembly 23 is installed between the waveguide 24 and eithermicrowave entry port 32 or 34 into the applicator chamber 37 to containthe pressure within the microwave reduction chamber and prevent anypotentially hazardous gas from entering the waveguide system back to themicrowave generator 10. The quartz pressure windows assembly 23 ispressurized with nitrogen from the nitrogen generator 11, and referencedto the internal microwave reduction chamber pressure. This insures thatexcess pressure cannot build up on the reduction chamber side of thequartz window assembly, resulting in a failure of the quartz window,and, with the introduction of air into the reduction chamber, create afire or explosion hazard. In a preferred embodiment, each microwavegenerator operates at a center frequency of 915 MHz+/−10 MHz. In anexpanded view in FIG. 4 this microwave energy is coupled from themicrowave generator, through a bifurcated waveguide assembly, into theapplicator chamber 37 via two (2) waveguides 32,34, which serve asrectangular conduits into each applicator chamber 37.

The waveguide entry into this applicator is via a three-portedbifurcated waveguide assembly 30, which equally divides theelectromagnetic wave of microwave energy prior to the two-plane entryinto the top of the applicator chamber, while maintaining electric fielddominance, The waveguide 32,34 inputs to the applicator chamber 37 fromthe bifurcated waveguide assembly 30 are in the same plane on the top ofthe applicator 37, but one waveguide plane 32 is oriented along thex-axis, while the other waveguide plane 34 is oriented along the y-axis.The split waveguide assemblies illustrated in FIG. 4 are designed so asto produce microwaves, which are essentially 90° out of phase. Thisresults in the generation of multiple modes of microwave energy withinthe applicator chamber 37 and elimination of the requirement for modestirrers, while providing a more uniform distribution of the microwaveenergy throughout the applicator 12.

The microwave energy is produced by the microwave generator andtransmitted into a WR-975 standard rectangular waveguide, fabricatedfrom high-conductivity, low-loss 1100S aluminum, instead of the moreconventional 6061 aluminum. The choice of low-loss aluminum results inless losses throughout the waveguide system from the microwave generatoroutput to the microwave reduction chamber inputs.

Generally, when mobile units are desired, with the microwave generatorsmounted on one trailer and the applicator mounted an adjacent trailer,it is customary to accomplish coupling of the microwave energy betweenthe two trailers via a ribbed, flexible waveguide assembly. However,there is also a tendency for those performing field alignment of the twotrailers to bend the flexible waveguide beyond its specified limits of+/−0.010 inches (0.254 mm), resulting eventually in a crack or fatiguefailure of the flexible waveguide assembly. Failure of any joint in thewaveguide assembly will cause microwave leakage into the surroundingarea, resulting in a hazard to personnel and potentially interferingwith communications equipment. It is understood that flexible waveguidesmay be used for this application, but are not shown in the drawings.

The microwave energy exits the microwave generator trailer and enters abifurcated waveguide assembly 30, which is illustrated in FIG. 4. Oneoutput connects to a right angle waveguide section, from which themicrowave energy enters directly into the microwave chamber 37. Theother output is presented to a two-section, long-radius, right anglewaveguide section, which accomplishes the turning of the microwaveenergy path 180°, while maintaining electric field dominance. Themicrowave energy enters a short straight section and anotherlong-radius, right angle waveguide section. The microwave energy is thencoupled into a right angle waveguide section and enters through thequartz pressure window assembly 23 directly into the microwave reductionchamber 37.

Although the waveguide entries 32,34 into the applicator reductionchamber 37 are in the same plane on the top of the applicator 12, theorientation of the two waveguide entries 32 and 34 relative to thecenterline of the applicator, is 90° to each other. One waveguide entrysection to each applicator entry point is parallel to the flow of theorganic materials, while the other is perpendicular to the flow of theorganic material. The other significant feature of this design is thatthe distance from the output from the bifurcated waveguide, whichcouples the microwave energy to the applicator entry point parallel tothe flow of the organic material, is physically much longer than theoutput feeding the perpendicular port. This additional length results ina different characteristic impedance at the microwave chamber entrypoint, a time delay in the microwave energy reaching the applicatorentry point, and a relative phase shift in the energy wave itself. Asstated previously, the microwave generator operates at a centerfrequency of 915 MHz+/−10 MHz. At this frequency, the effects ofadditional waveguide lengths and bends present a very noticeable changein the time/phase relationships due to the impedance mismatch. Theimpedance mismatch results in a phase shift of 90 electrical degrees.The significance of the 90° phase shift manifests itself in the type ofpolarization present in the microwave reduction chamber. Each microwaveinput from the bifurcated waveguide assembly is a linear polarized wave.When two linear polarized waves, separated in time quadrature by 90°,circular polarization occurs. In this invention, the impedance mismatch,phase shift in microwave inputs to the applicator, and resultingcircular polarization, along with the chosen frequency of operation, isa significant contribution to the microwave energy mixing within eachmicrowave reduction chamber, allowing more even microwave energydistribution throughout the entire applicator.

Microwave reduction occurs in a continuous mode, as opposed to a batchmode, and organic material is continuously, but synchronously, enteringand exiting the microwave applicator. During the entry and exit times,it could be possible that microwave energy could propagate into thesurrounding area, resulting in a possible hazard to personnel and createradio frequency (RF) interference. To prevent leakage of microwaveenergy from the active area of the microwave applicator, a device knownas an RF trap 38, containing a matrix or array of grounded ¼-wavelengthRF stubs (antennae), with ¼-wavelength spacing between the RF stubs inboth the x-plane and y-plane, are installed at each end of theapplicator to insure attenuation of microwave energy for compliance withleakage specifications of <10 mW/cm² maximum for industrial applicationsand <5 mW/cm² maximum for food applications.

The active area in the microwave chamber consists of a rectangularcavity, measuring 8 feet long (2.44 meters)×4 feet (1.22 meters) wide×2feet (0.61 meters) high, designed specifically for the microwave energycoupled from one (1) or two (2) microwave generators. This is referredto as a microwave reduction chamber or one applicator module. Multiplemicrowave reduction chamber modules may be connected together to form anapplicator. FIG. 1 illustrates a microwave reduction applicator whichincludes three (3) microwave reduction chambers, which receive microwaveenergy from five (5) microwave generators and five bifurcated waveguideassemblies, which result in ten (10) sources of microwave energy to theapplicator and even more uniform microwave energy distribution. Theapplicator also contains a continuous, self-aligning, closed mesh, 4feet (1.22 meters) wide, Type 304 stainless steel belt 19, whichtransports the organic material into the applicator at the entry port44, through the active area of the applicator 45, and out of the exitport 46.

Just as the applicator 12 and the microwave 10 are chosen to accommodatea specific throughput of scrap tire material equivalent to 100-8,000tires per day, the infeed 50 and outfeed 60 assemblies, along with themicrowave reduction chamber 37 are also sized volumetrically to processthe specified amount of material. As this invention is capable ofoperating in continuous mode, as opposed to batch mode, the feed systemsoperate independently, yet synchronously with the movement of thematerial on the belt 19 though the applicator reduction chamber 37.

Initially, the applicator reduction chamber 37 is purged with five (5)volumes of nitrogen gas to displace any air within, and is maintained ina slightly pressurized state, approximately 0.1 psig (0.689 kPa) abovelocal atmospheric pressure. This insures that no air migrates into theapplicator reduction chamber 37 during opening of either infeed 50 oroutfeed 60 shutter systems. Since the applicator is slightlypressurized, nitrogen will flow toward the sealed shutter assemblies,instead of air flowing into the microwave reduction chamber. Withreference to FIG. 3 and FIG. 4, the microwave reduction chamber is opento the bottom slide 53 b of shutter 53 and the top slide 61 a of shutter61. If any seal leakage occurs at the shutter interface, the nitrogendirection of flow is always from the applicator into the shutterassembly. At startup, all slides on infeed shutter system 50 and outfeedshutter system 60 are closed.

The infeed system 50 includes three sliding shutter assemblies, 51, 52,and 53. The sequence of operation is as follows: Initially, nitrogen gasis applied to infeed shutters 51, 52, and 53 until five (5) volumes havebeen purged through the shutters to atmosphere. The top slide 51 a ofshutter 51 opens and receives material from an optional hopper orexternal conveyor belt. The bottom slide 51 b of shutter 51 remainsclosed. Dependent upon desired throughput, the load cell 54 under thetop slide allows material to enter shutter 51 until the prescribedamount of material has been deposited. At this time, the top slide 51 acloses and nitrogen purge gas is applied to shutter 51. After five (5)volumes of nitrogen have purged shutter 51, the bottom slide 51 b opens,along with slide 52 a of shutter 52, located directly below shutter 51.After the material drops through from shutter 51 into shutter 52, thebottom slide 51 b and top slide 52 a close. After five (5) volumes ofnitrogen have purged shutter 52, the bottom slide 52 a opens, along withslide 53 a of shutter 53, located directly below shutter 52. After thematerial drops through from shutter 52 into shutter 53, the bottom slide52 b and top slide 53 a close. After five (5) volumes of nitrogen havepurged shutter 53, the bottom slide 53 b opens, and the material dropsonto conveyor belt 37. Conveyor belt 37 transports the material beneaththe RF trap's 38 array of choke pins into the active area of themicrowave reduction chamber. Based upon the type of material, throughputrequired, and microwave power applied, the conveyor belt 37 transportsthe material through the applicator 12 at a preset speed.

The outfeed system 60 includes two sliding shutter assemblies, 61 and62. The sequence of operation is as follows. Initially, nitrogen gas isapplied to outfeed shutters 61 and 62 until five (5) volumes have beenpurged through the shutters to atmosphere. When belt 37, along with itsreduced material reaches the outfeed shutter system, nitrogen purge gasis applied to outfeed shutter 61 to displace any air. The top slide 61 aof shutter 61 opens and the reduced material drops from conveyor belt 37into outfeed shutter 61. The bottom slide of shutter 61 b remainsclosed. After the material drops from the belt into shutter 61, the topslide 61 a closes. Nitrogen purge gas is applied to shutter 62 untilfive (5) volumes have been purged through shutter 62 to displace anyair. Then, the bottom slide 61 b of shutter 61 and the top slide 62 a ofshutter 62 open, and the material falls into shutter 62, locateddirectly below shutter 61. When all of the material has dropped intoshutter 62, the bottom slide 61 b of shutter 61 and the top slide 62 aof shutter 62 closes. Nitrogen gas is applied to shutter 63 until five(5) volumes have been purged through shutter 63. Then the bottom slide62 b of shutter and the top slide 63 a of shutter 63 open, and thematerial falls into shutter 63, located directly below shutter 62.Finally, the bottom slide 63 b of shutter 63 opens and the reducedmaterial drops into an optional grinder, onto an external conveyor belt,into an optional hopper, or is removed by a vacuum system to a storagearea. Sequencing of the infeed system, conveyor belt speed control,outfeed system, magnetrons and nitrogen purge gas system is under PLCprogram control at all times. An alternate infeed and outfeed systemincludes a nitrogen-purged, multiple-chamber rotary airlock system.

The internal walls of the applicator are made from either low-loss 1100Saluminum plate or Type 304 stainless steel, depending upon theapplication. High temperature applications in excess of 900° F. (482°C.) and corrosive atmospheres require the use of Type 304 stainlesssteel. Microwave reduction of scrap tires results in an equilibriumtemperature occurring at 680° F. (360° C.) in a relatively non-corrosiveatmosphere, therefore, 1100S aluminum plate is the material of choice.In microwave reduction applications such as plastics, particularlypolyvinyl chlorides (PVC), hydrochloric acid is produced in voluminousamounts, contributing to surface corrosion, as well as stress corrosioncracking; therefore, Type 304 stainless steel is preferred The type ofgaskets used around the microwave viewing/access doors 48 for gascontainment requires a round silicone gasket for non-corrosiveatmospheres or a Teflon-enclosed epoxy gasket for corrosive atmospheres.In either application, a carbon-filled Type 304 stainless steel meshgasket is used for microwave containment around the viewing/access doors48. The hydrocarbon gases exit through a transition plenum duct from arectangular cross-section at the applicator to a circular cross-sectionto accommodate a ten (10) inch (25.4 cm) pipe containing a tee, whosebranch is connected to a rupture disk 44 rated at 15 psig (103.4 kPa),and a rotary-disk butterfly valve 41. The applicator discharge valve 41serves to control the applicator static pressure, which is the result ofthe hydrocarbon gases generated during microwave reduction of theorganic materials plus nitrogen purge gas.

The five (5) microwave generators, as shown in FIG. 1, consist of five(5) magnetrons, each rated at 100 kW, five (5) circulators with waterloads, each rated at 100% power generated by their respectivemagnetrons, and five (5) switched-mode power supplies (SMPS), whichcontain all power and control signals, along with metering for themagnetrons and control electromagnets, plus digital and analoginterfaces to the Programmable Logic Controller (PLC). The SMPS operatesat a typical efficiency of 91%, and eliminates the less efficient,heat-producing power transformer, along with the six-phase bridgerectifier assembly, SCR controllers, filtering, and associated wiring.The additional benefit of the SMPS is that, in the event of an immediateshutdown, the output voltage of the SMPS almost immediately (<10 mS)decreases to zero (0) volts. However, in the case of the transformerpower supply, the internal capacitance between the transformer windings,can store a lethal voltage for several hours. The other undesirableeffect from the transformer power supply is that after a shutdown, thestored charge within the transformer can cause the magnetron to operateoutside its rated operating envelope and cause premature magnetronfailure.

The PLC provides metering, sequencing and control of the microwavegenerator, conveyor motors and applicator controls. The only additionalrequirement is cooling water in the amount of 5 gallons per minute(18.93 liters/minute) per 100 kW magnetron and 3 gallons per minute(11.35 liters per minute) per circulator water load. Each microwavegenerator is a two-door enclosure with front and rear door access,measuring 48 inches (1.22 meters) long×84 inches (2.13 meters) high×24inches (0.61 meters) deep, which is a footprint reduction fromconventional microwave generator systems.

To process additional material or increase the throughput, one may addadditional microwave generators, microwave applicator modules, increasebelt speed, or increase the organic material bed depth proportionally.For small variations in the power requirement due to slightinconsistencies in the material being processed, the belt speed may beadjusted to change the dwell or residence time of the organic materialwithin the applicator. Belt speed control is accomplished by changingthe conveyor speed setpoint on the touchscreen, mounted on the front ofthe Main Control Panel, adjacent to the line of microwave generatorpanels, as illustrated in FIG. 1.

It has been determined that the process characteristics relative tothroughput and power consumption are linear from minimum to maximumthroughput. For example, energy consumption during microwave reductionof scrap tires at 915 MHz is 1.80 kW-hr per tire from 100 tires per8-hour shift to 8,000 tires per 24-hour day, when utilized with anappropriate applicator length, bed depth and microwave power level. Thisinvention allows the addition of microwave generators and relativeappurtenances in sets of six, along with an extension of the applicatoras dimensionally defined above.

The standard design, which supports the majority of organic materialreduction processes with high power density microwaves, contains three(3) microwave modules per applicator. Through careful design, thismodular concept may be extended to include a maximum of 80 microwavegenerators or 16 modules within one applicator, in a stationary design.

In one aspect of the invention, the design of the unit is a mobiledemonstration unit, with the microwave generators and control cabinets,along with the Main Control Panel, scrubber, nitrogen generator andchiller mounted in one trailer and the microwave applicator assembly andelectrical generator mounted on an adjacent trailer.

Microwave system control is accomplished by the use of a ProgrammableLogic Controller (PLC) with Digital and Analog Input/Output (I/O)Modules and a Data Highway to a Remote Terminal Unit (RTU), which areall mounted in the Main Control Panel (MCP). The RTU is also known as anOperator Interface Terminal (OIT), as the touchscreen on the OIT is theoperating interface to the microwave reduction system. PLCcommunications modules are mounted in each microwave generatorenclosure, which permits continuous bidirectional communication betweenthe PLC and the OIT or touchscreen. The PLC program provides continuoussequencing, monitoring and control functions in real time. The PLCprogram also communicates along a data highway to display alarm/shutdownstatus and operating parameters on the touchscreen The touchscreenprovides multiple displays in both digital and analog formats in realtime. The summary status touchscreen indicates power output, reflectedpower, anode current, anode voltage, filament current, electromagnetcurrent, generator cabinet temperatures, applicator temperatures andpressures, internal and external water temperatures, hydrocarbon vaporflow rates, process operating curves, PID control loop status, andparametric data from the nitrogen generator, chiller, process condenser,and scrubber, all in real time.

Additional magnetron protection is insured by a directional couplersystem, which monitors forward and reflected power, and de-energizes thehigh voltage to the magnetron in the event of sensing more than 10%reflected power. An arc detection system further protects the magnetron,three-port circulator, and waveguide by de-energizing the high voltageupon detection of arcing within the applicator. Fire detection withinthe applicator includes infra-red (IR) sensors, smoke detection andrate-of-rise temperature detectors plus combustible gas detectorsadjacent to the applicator, which are all wired in series with thesafety shutdown system. A multiple-bottle nitrogen backup system servesas a deluge system in the event of a fire, plus provides nitrogenbackup, in the event of a nitrogen generator failure.

Any shutdown parameter, which exceeds its preset limit, initiates animmediate shutdown of the high voltage system, and enables the safetyshutdown system to proceed through an orderly and controlled shutdown.The safety shutdown system includes both fail-safe hardwired circuitryand PLC shutdown logic, along with local and remote emergency stopbuttons to insure maximum protection for operating and maintenancepersonnel and equipment. Microwave access/viewing doors, microwavegenerator doors, and power supply enclosure doors are provided withfail-safe, safety switches, which are interlocked with the PLC program,and monitored during microwave operation to protect operating andmaintenance personnel from exposure to microwave energy and shockhazards.

Further, the applicator access/viewing doors contain slotted¼-wavelength chokes and dual fail-safe safety switches, interlocked withthe PLC program to immediately (10 mS) switch off the high voltage, inthe event of opening during operation. Switching off the high voltageimmediately suspends magnetron operation, and hence eliminates anyoutput of microwave energy. Other safety equipment integrated into thisinvention include a dual-keyed, fused manual disconnect for the mainpower source from the electrical generator or the customer's utility anda high speed molded case breaker, with electrical trip and shunt voltagetrip tied to the shutdown system. Finally, a copper ground bus bardimensioned 24 inches (0.61 meters) long×2 inches (5.08 cm) high×¼ inch(6.35 mm) thick is provided to insure absolute ground integrity from themain power source to all equipment included with this invention.

PLC programming utilizes standard ladder logic programming, reflectinghardwired logic for digital inputs and outputs, whose logic functionsare programmed with Boolean expressions. Special function blocks,including preset setpoints, are used for analog inputs and outputs. Theemergency shutdown switches are normally closed (push to open), the lowlevel switches must reach their setpoint before operations may besequenced, and the high level switches will open upon exceeding theirsetpoint. Any open switch in the series shutdown string will cause themaster shutdown relay to de-energize, which results in de-energizing thehigh voltage circuits and forces the PLC to execute an immediate,sequential, controlled shutdown.

The best mode for carrying out the invention will now be described forthe purposes of illustrating the best mode known to the applicant at thetime of the filing of the application. The examples are illustrativeonly and not meant to limit the invention, as measured by the scope andspirit of the claims.

A summary of recorded data from microwave excitation of scrap tirematerial is presented in Table 2. All data were the result of exposingshredded scrap tire material to high-power density microwave energy inan approximately one cubic meter (1 m³), stainless steel applicator, fedby microwave inputs from three (3) magnetrons, each capable ofgenerating 3 kW of microwave power at approximately 50% efficiency andoperating in batch mode at 2450 MHz. Variations in the output gascompositions, as well as the amounts of gas and oil, were the result ofvarying the applicator pressure and hydrocarbon vapor residence time.Variations in the applicator pressure and hydrocarbon vapor residencetime were the result of varying the position of the applicator outputvalve. It was observed that higher applicator pressure (2-10 psig)(13.8−6.9 kPa) and lower flow produced a longer hydrocarbon vaporresidence time, which resulted in production of more paraffins, lessolefins, less arenes and naphthenes, and subsequently less oil.Conversely, lower applicator pressure (0.1-1.0 psig) (0.69−6.9 kPa)produced a shorter hydrocarbon vapor residence time, which resulted inproduction of less paraffins, more olefins, more arenes and naphthenes,and subsequently more oil.

Applicator pressure was set statically during the nitrogen purge cycleat the beginning of each test between 0.1 and 0.5 psig (0.69−3.45 kPa).Steady-state temperatures reached at equilibrium, occurred atapproximately 680° F. (360° C.), with a hydrocarbon vapor residence timeof approximately 285 milliseconds (mS).

To verify the effects of pressure, temperature and residence time on thegaseous and liquid fuels produced, pressure within the applicator wasincreased to a level between 1.0 and 10.0 psig (6.9-69 Pa) by adjustingthe applicator discharge valve position closed between 100 and 50% ofstroke, respectively. The corresponding pressure setup changes produceda new steady-state temperature, which stabilized in a range of 842-680°F. (450-360° C.), along with a corresponding change in the hydrocarbonvapor residence time within the applicator in a range of 400-80milliseconds, respectively. Applicator pressure, temperature, andhydrocarbon residence time varied inversely with the closing stroke(less open) of the applicator discharge valve.

These parametric process changes produced oil:gas ratios from ˜10%Oil:90% Gas to ˜90% Oil:10% Gas, The microwave test data in Table 2provides an insight into the possible variations of output fuel(oil:gas) ratios from scrap tires. As the primary objective of the testwas to maximize the production of high-Btu syngas, the majority of thetest data exists at the oil:gas ratio of 25% Oil:75% Gas, Representativedata points are given in Table 2, which illustrate process output fuelratios throughout the ranges stated above. In addition, these data havebeen extrapolated for several variations of oil:gas ratios throughoutthe stated ranges, in order to produce the operating performance graphsillustrated in FIG. 7, FIG. 8, and FIG. 9. These graphs can be utilizedto determine an indication of selected operating points.

At the elevated pressures, temperatures, and increased residence times,the amount of butane is significantly reduced, resulting in an increasein propane, and subsequently ethane. There were no olefins, arenes, ornaphthenes present in the syngas produced. As a result of minimalolefins and aromatics in the hydrocarbon vapor stream before thecondensor, the amount of oil is also minimal. Through monitoring of thesyngas stream after the scrubber with a gas chromatograph, it isapparent that increased pressure within the applicator causes a directeffect on equilibrium temperature, gas residence time, but an inverseeffect of the amount of butane.

The reduced amount of butane, and propane for that matter, in thesyngas, provides a wider selection of commercially available InternalCombustion Gas Turbines (ICGT's) for combustion of the syngas. Thehigh-Btu syngas heat value and its relation to a choice of an ICGT isonly an issue if the syngas application is gas production orcogeneration of electricity. For sales gas purposes, recovery of thebutane and propane from the syngas provides an additional revenue streamfor the client. Regardless of the application, increasing the residencetime in the applicator is a more cost-effective method to reduce thebutane and propane, than to incorporate a gas stripper system in themicrowave-based tire reduction process.

The conclusions concerning applicator pressure effects on temperatureand hydrocarbon vapor residence time, along with types of by-productsformed, were confirmed by a four-channel Gas Chromatograph (GC),employing a dual oven, with two (2) Flame Ionization Detectors, (FID),one (1) Thermal Conductivity Detector (TCD), and one (1) ElectronCapture Detector (ECD). Separate 100-meter capillary columns wereinstalled in each oven. The gas chromatograph carrier gas washigh-purity hydrogen (H₂). Adjustable pressure reducing regulators withpressure gauges, were installed on all gas cylinders. Stainless Steel,Type 304, tubing was installed between the gas ports on the applicatorand the gas chromatograph.

The applicator contained dual inlet ports for purge gas high-puritynitrogen (N.sub.2), and one inlet port each for high-purity hydrogen(H₂) (reducing gas), and plasma enhancing/purge gas high-purity argon(Ar). A direct-reading bubble-type flowmeter was installed on theapplicator at the purge gas inlet and a turbine-type mass flowmeter wasinstalled in the applicator exhaust gas outlet piping after thedischarge valve.

Other tests that were conducted, using this same microwave reductionsystem, included utilization of nickel (Ni), platinum/molybdenum(Pt/Mo), and zeolite catalysts to observe the enhanced reduction of theheavier hydrocarbons contained in the hydrocarbon vapor stream. Inanother series of tests, Argon was introduced into the applicator toobserve the highly, energetic reactions created by themicrowave-generated plasma. Catalytic conversion, plasma generation, andfree-radical reduction of organic compounds through microwaveexcitation, will be addressed separately. Microwave-generated plasma inconjunction with catalyst-enhanced reduction resulted in increasedproduct yields of syngas, with characteristics more similar to naturalgas than process gas, with improved efficiency.

TABLE 2 Shredded Scrap Tire Reduction Test Results at 2450 MHz InitialFinal Mass Mass of MW Total kW- Test Mass Mass Change Mass of Gas % Pwr.Time hr/ No. (lbs) (lbs) (lbs) Oil (lbs) % Oil (lbs) Gas (kW) (hr) Tire1 7.998 6.614 1.384 0.327 23.63 1.057 76.37 6.6 1.912 1.58 2 10.0008.102 1.898 0.794 41.83 1.104 58.17 8.2 1.833 1.50 3 10.163 8.201 1.9620.576 29.36 1.386 70.64 9.0 1.750 1.55 4 8.579 6.693 1.885 0.316 16.761.569 83.24 9.0 2.133 2.24 5 8.512 6.449 2.063 0.325 15.75 1.738 84.259.0 2.133 2.26 6 8.823 7.013 1.810 0.472 26.08 1.338 73.92 9.0 2.1332.18 7 8.538 6.761 1.777 0.391 22.00 1.386 78.00 9.0 2.133 2.25 8 8.8186.815 2.003 0.326 16.28 1.681 83.92 9.0 2.133 2.18 9 7.716 6.566 1.1500.661 57.48 0.489 42.52 9.0 3.000 3.50 10 7.716 6.435 1.281 0.111 8.671.170 91.33 9.0 3.500 4.08 11 9.987 8.461 1.526 0.549 35.98 0.977 64.029.0 2.133 1.92 12 15.625 12.523 3.102 0.782 25.21 2.320 74.49 9.0 3.5002.02 13 20.568 14.507 6.061 1.068 17.62 4.993 82.38 9.0 4.000 1.75 1420.552 14.838 5.714 1.155 20.21 4.559 79.79 9.0 4.000 1.75 15 13.22812.162 1.066 0.319 29.92 0.746 69.98 9.0 2.217 1.51 16 13.228 12.2640.964 0.204 21.16 0.760 78.84 9.0 2.167 1.47 17 4.409 3.773 0.636 0.36156.76 0.275 43.24 9.0 3.333 6.80 18 8.818 6.309 2.509 0.604 24.07 1.90575.93 9.0 3.333 3.40 19 4.409 3.767 0.642 0.305 47.51 0.337 52.49 9.03.667 3.05 20 8.818 6.342 2.476 0.514 20.76 1.962 79.24 9.0 3.667 3.7421 4.409 4.089 0.320 0.249 77.81 0.071 22.19 9.0 3.667 7.49 22 8.8186.493 2.325 0.395 16.99 1.930 83.01 9.0 3.667 3.74 23 13.228 9.725 3.5030.837 23.89 2.666 76.11 9.0 3.667 2.49 24 13.228 11.220 2.008 0.57128.44 1.437 71.56 9.0 2.500 1.70 25 13.228 11.526 1.702 0.551 32.371.151 67.63 9.0 2.500 1.70 26 9.913 6.946 2.967 0.823 27.72 2.146 72.289.0 2.500 2.27 27 10.582 7.192 3.390 0.905 26.70 2.484 73.30 9.0 2.5002.13 28 10.582 7.388 3.194 0.751 23.50 2.444 76.50 9.0 2.500 2.13

As illustrated in provisional patent application Ser. No. 60/825,002filed on 8 Sep. 2006, increasing both the temperature from (572° F.→680°F.) and the microwave power (375 kW→600 kW) using a residence time of˜285 ms, produces both a change in the composition as well as the BTUcontent of the gaseous constituent. The “original” data column is foundin provisional patent application Ser. No. 60/766,644 filed 2 Feb. 2006while the “revised” data and comparison are found in provisional patentapplication Ser. No. 60/825,002 filed on 8 Sep. 2006. The “revised”liquid fuel characteristics are similar to those of No. 2 diesel fuel.The magnetron efficiency must be a minimum of 88% to achieve the“revised” results. All measured experimental percentages areapproximately +/−2%.

TABLE 3 Gas Ref. Conditions: 14.696 psia, 60° F. Syngas and Liquid FuelAnalyses Original (Avg.) Revised Gas Fuel Analysis: wt. % vol. % wt. %vol. % Methane: 15.86 30.984 27.04 42.132 Ethane: 32.15 33.511 50.4341.924 Propane: 7.51 5.338 9.68 5.488 i-Butane: 1.16 0.626 0.07 0.030n-Butane: 32.64 17.601 2.10 0.903 Nitrogen: 10.68 11.940 10.68 9.523 GasCharacteristics: Original (Avg.) Revised Units Molecular Weight, MW:31.3189 24.9790 — Specific Gravity, SG: 1.0812 0.8624 — Density, ρ:0.0817 0.0655 lbs/ft³ Specific Volume, v: 12.2429 15.2762 ft³/lbCompressibility, Z: 0.9895 0.9944 — Specific Heat, C_(P): 0.4233 0.4425Btu/lb-° F. Specific Heat, C_(v): 0.3451 0.3524 Btu/lb-° F. Ratio ofSpecific Heats, k: 1.2265 1.2557 — Heat Value, HHV: 1,635 1,217 Btu/ft³Heat Value, LHV: 1,498 1,336 Btu/ft³ Gas Constant, R: 60.397 69.586ft-lb_(f)/lb_(m)-°R. Liquid Fuel Analysis Cetane Index (ASTM D613) 25Viscosity @ 40° C. (ASTM D445) 1.2 cst Specific Gravity (ASTM 4052) 0.89API Gravity @ 60° C. (ASTM 4052) 33.4 Initial Boiling Point (ASTM D86)63° C. 50% st. Boiling Point (ASTM D86) 186° C. Final Boiling Point(ASTM D86) 347° C. Elemental Iron Content (ASTM D3605) 2 ppm ElementalSodium Content (ASTM D3605) 2 ppm Elemental Silicon Content (ASTM D3605)180 ppm Other Trace Metals Content (ASTM D3605) <1 ppm Sulfur Content:(ASTM D1552) 0.48 wt. % Carbon Residue Content (ASTM D524) <0.01 wt. %Ash Content: (ASTM D482) <0.007 wt. % Copper Strip Corrosion: (ASTMD130) 2

As illustrated in provisional patent application Ser. No. 60/825,002filed on 8 Sep. 2006, a comparison of the original average tireperformance data with “original” average gas data and “revised” gas datais provided in Table 4 below.

TABLE 4 Comparison of Tire Performance Data Based on Average and RevisedGas Analyses Avg. Rev. Avg. Rev. Gas Gas Gas Gas Process Parameter(60:40 Oil:Gas) Units (60:40) (69:31) (60:40) 69:31) Demo Unit - GasAnalysis at 14.696 psia, 60° F. Scrap Tire Feedstock: Tires/day 20 206,000 6,000 Total Operating Hours/Day Hours 1 1 24 24 Total Mass Flow:lbs/min 6.667 6.667 83.333 83.333 Total Heat Value (15,500 Btu/lb)MMBtu/hr 6.200 6.200 77.500 77.500 Gaseous Fuel (40% Wt.): Gas Sample(avg.) with 10.68 wt. % Nitrogen Hydrocarbons (HC) + N₂: lbs/min 1.7721.375 22.144 17.189 Nitrogen (N₂) Mass Flow lbs/min 0.189 0.147 2.3651.836 HC Mass Flow - (H₂S, HCl, HBr): lbs/min 1.583 1.228 19.779 15.353Total Volumetric Flow: ft³/min 21.688 21.007 271.11 262.58 SpecificVolume: ft³/lb 12.243 15.276 12.243 15.276 Volumetric Heat Value (HHV):Btu/ft³ 1,635 1,336 1,635 1,336 Volumetric Heat Value (LHV): Btu/ft³1,498 1,217 1,498 1,217 Total Heat Value (HHV): MMBtu/hr 2.128 1.68426.601 21.049 Total Heat Value (LHV): MMBtu/hr 1.949 1.534 24.359 19.181Gas Fuel Equiv. Elect. Pwr. (LHV): kW 191 150 2,388 1,880 H₂S Gas toLiquid Scrubber: Total Mass Flow (H₂S): lbs/min 0.0124 0.0124 0.15540.1554 Total Volumetric Flow: ft³/min 0.1407 0.1893 1.7633 1.7633Specific Volume: ft³/lb 11.347 15.265 11.347 15.265 Volumetric HeatValue_(MIXTURE) (HHV): Btu/ft³ 1,633 1,334 1,633 1,334 Volumetric HeatValue_(MIXTURE) (LHV): Btu/ft³ 1,496 1,215 1,496 1,217 Total Heat Value(HHV): MMBtu/hr 0.0138 0.1515 0.1668 0.1411 Total Heat Value (LHV):MMBtu/hr 0.0126 0.1380 0.1528 0.1288 Residual Hydrogen Sulfide:ppm_(wt.)/min. 1.24 15.54 15.54 (1.24 × 10⁻⁶ lb/min) Other Gases toScrubber: Total Mass Flow (HCl): lbs/min 0.000470 0.0058 0.0058 TotalVolumetric Flow: ft³/min 0.00499 0.0615 0.0615 Specific Volume: ft³/lb10.607 10.607 10.607 Residual Hydrogen Chloride: ppm_(wt.)/min 0.0470.58 0.58 (0.047 × 10⁻⁶ lbs/min) Total Mass Flow: (HBr): lbs/min 0.00420.0523 0.0523 Total Volumetric Flow: ft³/min 0.0201 0.2500 0.2500Specific Volume: ft³/lb 4.780 4.780 4.780 Residual Hydrogen Bromide:ppm_(wt.)/min 0.42 5.23 5.23 (0.42 × 10⁻⁶ lbs/min) Liquid Fuel (60% Wt):Total Mass Flow: lbs/min 2.390 2.747 29.876 34.333 Heat Value (HHV):Btu/lb 19,600 19,600 19,600 19,600 Total Heating Value (HHV): MMBtu/hr2.811 3.230 35.134 40.375 Liq. Fuel Equiv. Elect. Pwr (HHV): kW 275 3173,444 3,957 Total Gas/Liquid Fuels: Total Heat Value (Gas + Liquid)MMBtu/hr 4.759 4.764 59.494 59.556 Total Elect. Equiv. (÷3411.8 kW/Btu)kW 1,395 1,396 17,440 17,456 Demo Unit - Avg. Gas Analysis at 60° F.Scrap Tire Feedstock: Tires/day 20 20 6,000 6,000 Total OperatingHours/Day Hours 1 1 24 24 Elect. Pwr. Generation Summary: Gas Sample(avg.) with 10.68 wt. % Nitrogen Electrical Power - ICGT: (× 0.35) kW488 489 6,104 6,018 Elect. Pwr - Gen. Out.: (× 0.985 × 0.97) kW 466 4675,832 5,837 Liq. Fuel Equivalent Elect. Power kW 275 317 3,444 3,957 GasFuel Equivalent Elect. Power: kW 191 150 2,388 1,880 Microwave Power otProcess: kW 30.16 35.26 377.06 440.79 Elect Pwr Req'd by Microwave:(÷0.88) kW 34.27 40.07 428.48 500.90 Ancillary Losses: Less Elect. Pwr -N₂ Gen.: kW 11.19 11.19 22.38 22.38 Less Elect. Pwr - Scrubber: kW 1.121.12 2.24 2.24 Less Elect. Pwr - Chiller (Mag/P.S./CND): kW 9.12 9.1280.55 85.87 Total Ancillary Loads: kW 21.43 21.43 105.17 110.49 MW PowerRequirement: kW 34.27 40.07 428.48 500.90 Total Elect. Pwr. Req'd kW55.70 61.50 533.65 611.39 Net Electrical Power for Export: kW (Gas Fuel)+135 +88.5 +1,854 +1,269 Other By-Products: Carbon/Carbon Black/MOFMixture: CB w/Metal Oxides, Fillers (MOF's): lbs/min 1.913 1.913 23.91523.915 Metal Oxides, Fillers (MOF's): lbs/min 0.289 0.289 3.618 3.618Net Carbon Black: lbs/min 1.624 1.624 20.297 20.297 Carb. Black Ht.Value (14,096 Btu/lb) MMBtu/hr 1.374 1.374 17.166 17.166 OtherBy-Products: Steel Plated High-Carbon Steel: lbs/min 0.770 0.770 9.6259.625 Energy Balance: Tire Feedstock: MMBtu/hr 6.200 6.200 77.500 77.500Less Carbon Black: MMBtu/hr 1.374 1.374 17.166 17.166 Less Liquid Fuel:MMBtu/hr 2.811 3.230 35.134 40.375 Less Gaseous Fuel_(LHV): MMBtu/hr1.949 1.534 24.359 19.181 Less Hydrogen Sulfide_(LHV): MMBtu/hr 0.0130.014 0.153 0.128 Total Energy Recovered: MMBtu/hr 6.147 6.152 76.81276.850 Net Energy Difference: MMBtu/hr −0.053 −0.048 −0.688 −0.650MMBtu/hr × 293.1 × 0.35 × 0.985 × 0.97 = kW equiv. −5.195 −4.705 67.43463.710 % Difference −0.85 −0.77 −0.90 −0.84 Magnetron Heat Load (12%):Btu/hr 14,022 16,411 175,435 205,083 Control Panel Heat Load [P.S](10%): Btu/hr 12,991 15,190 162,432 189,886 Gas Condensor Heat Load(QΔTC_(p)): Btu/hr 24,365 22,634 298,072 282,948 Total Heat Load: Btu/hr51,378 54.235 635,939 677,917

When the invention is used in the reduction mode, it is envisioned thatboth decrosslinking, depropagation, and depolymerization reactions arecontemplated and within the scope of this invention. In one suchembodiment, waste organic materials, such as scrap tires, are gasifiedby the continuous application of high power density microwave energy,using a continuous, self-aligning, stainless steel belt with 4 inches(10.16 cm) material retaining sides to produce stable by-products, whichincludes essentially ethane and methane.

When the invention is used in this mode, a process is provided for therecovery of specified gaseous products and includes maintaining thehydrocarbon vapor stream at least as high as an equilibrium temperature,above which the specified products are thermodynamically favored,followed by rapidly cooling the hydrocarbon vapor stream to atemperature at which the specified products are stabilized.

When gasifying shredded scrap tires, the preferred gaseous product is ahydrocarbon vapor stream, which consists of substantially ethane andmethane in a ratio of two parts ethane to one part methane by weightplus 10% by weight nitrogen. A product stream, which varies from thepreferred range, but is still acceptable, includes ethane, methane, andpropane, at two parts ethane, to one part each of methane and propane,in addition to 10% by weight nitrogen. Another product stream, whichvaries further from the preferred range, but is also acceptable,includes ethane, butane, methane, and propane, at two parts each ofethane and butane to one part methane, and one part propane by weight,in addition to 10% by weight of nitrogen. Mixtures of ethane/methane, aswell as those also containing propane and butane, have very high heatvalues, even when diluted with 10% nitrogen by weight, but can bedirectly injected into some ICGT combustion chambers without furthertreatment.

Conditions within the microwave applicator are selected so as to producethe desired components or gas:oil ratio in the hydrocarbon vapor stream.In a preferred embodiment, no liquid products, e.g., oils, will beproduced. In order to insure that a 2:1 ratio of ethane:methane isproduced, the feed rate, residence time, power density, energy levelfrom the magnetrons is controlled as well as the pressure andtemperature within the applicator.

In a typical scrap rubber tire reduction case, the following conditionswill produce the desired ethane:methane mixture. The preferredapplicator will contain anywhere from 3 to 10 microwave chambers,preferably six (6) magnetrons, each magnetron operating at about 915MHz. Under these conditions, at steady-state operation, a residence timeof approximately 285 milliseconds in the applicator, will result in atemperature in the applicator of about 680° F. (360° C.). Typically, theprocess pressure within the applicator will range from 0.1 to 0.5 psig(0.69−3.45 kPa). As kinetics favor reactions below equilibrium, theintermediate reactions release free hydrogen, which furthers thereduction of more complex organic molecules, leading to furtherbreakdown, and a higher rate of reduction. The chemical reactions areexothermic in nature.

For crosslinked styrene-butadiene rubbers (SBR), the production ofgaseous products includes the initial depolymerization of the sulfurcrosslinks, followed by the addition of further microwave energy overtime, resulting in the depropagation and breakdown of the two mainpolymers to form the desired products. At temperatures above about 680°F. (360° C.), depending on the feedstock, thermodynamics favor methaneand ethane over the original polymers or other polymers. Accordingly,once depropagation and depolymerization is complete by maintaining thosetemperatures and applying the requisite microwave energy over a periodof time, the gas stream remains stable at the high temperature. Veryrapid cooling will prevent repolymerization or recombination of the gasconstituents. The hydrocarbon gas stream is then flash-cooled,preferably down to about 100° F. (38° C.), to stabilize the ethane andmethane at the lower temperatures. The residence time of the gas streamin the applicator is controlled in large part by the total pressureimposed by the nitrogen purge gas and the pressure developed by theformation of the hydrocarbon gaseous products of reduction, inconjunction with the flow rate set by the eductor at the inlet of thegas scrubber. The hydrocarbon vapor stream is then scrubbed to removehydrogen sulfide, hydrogen chloride, and hydrogen bromide gases,hereafter referred to as contaminants.

The hydrocarbon vapor stream is scrubbed of its contaminants by adry-contact, top-fed packed tower, packed with limestone and dolomite,while maintaining the gas temperature above the equilibrium point. Acompressor must be used to force the hydrocarbon vapor stream throughthe scrubbing tower. The clean hydrocarbon vapor stream then exits andis flash cooled in an aluminum air-to-air heat exchanger, with liquidnitrogen acting as the cooling medium. The dry scrubber removesapproximately 95-97% of the contaminants.

Alternately, the hydrocarbon vapor stream is scrubbed of itscontaminants, preferably by a gas-contact, liquid scrubber, containing adilute, aqueous solution of sodium hydroxide (NaOH) and sodiumhypochlorite (NaOCl). The liquid scrubber eliminates the requirement fora compressor, as the scrubber eductor effects a 6 inch (15.24 cm) vacuumon the hydrocarbon gas stream flowing at approximately 285 acfm (484.2m³/hr). The scrubber is designed with two 12 inch (30.48 cm) diametertowers, containing special packing to minimize the overall height. Theentire scrubber system is manufactured from high-density polyethylene.The liquid scrubber removes 99.99% of the contaminants, requires lessspace, and is more cost-effective in regards to the consumable chemicalsthan the dry scrubber. The scrubber tank containing chemical solutionsis mounted under the twin packed-towers to provide stability to thetowers in the mobile version. Column height, diameter and chemical tanksize is determined by the process gas equilibrium and the desiredremoval efficiency.

Control of the liquid scrubber with its blowdown, makeup, and scrubbingcycles, is accomplished by the same PLC program, used for control of themicrowave reduction process. In the mobile version of the invention, theliquid scrubber is installed in the microwave generator trailer, forwardof the microwave generators and power distribution center. In the mobileversion of the invention, makeup water for this system is pumped from awater reservoir installed under the applicator on the applicatortrailer. Regardless of which scrubber is used, the hydrocarbon vaporstream exits the applicator and passes through a multiple-pass,water-cooled water-to-air process gas condenser. The process gascondensor provides cooling and stabilization of the gaseous products,while allowing recovery of the oil products. Residence time in thecondensor is sufficient to allow the oil forming reactions to go tocompletion, while permitting the lighter, paraffin gases to stabilizeand be drawn to the liquid scrubber.

A blanketing or purge gas is often used, nitrogen and argon being thetwo preferred gases. This gas may be supplied through drilled orificesthrough the choke pins in each R.F. trap. Nitrogen is preferred due toits lower cost, but has the potential of reacting with aromatic gaseousproducts of reduction, such as benzene, toluene, xylene, etc. Withprecise control of the applied microwave power and hydrocarbon gasresidence time, in order to achieve the necessary reduction, formationof nitro-arene compounds can be avoided. Nitrogen gas is provided by aNitrogen Generator, which includes a compressor and molecular sieve toproduce relatively high-purity (≧98% purity) nitrogen.

The nitrogen generator is backed up with eight standard nitrogenbottles, in the event of a failure, while also acting as a deluge systemin the event of a fire in the applicator. In the mobile version of theinvention, the complete nitrogen system is installed in the microwavegenerator trailer forward of the hydrocarbon vapor scrubber. Oxygensensors are also installed in this trailer to warn of a nitrogen leak,to prevent asphyxiation due to displacement of the air by the nitrogen.

Alternately, argon can be used since it is an inert gas, but at a highercost, although lowered accounts are typically required due to its highermolecular weight. When operating this invention in the plasma mode,argon is used as both the plasma gas and the blanketing gas, therebyeliminating the possible formation of unwanted nitrogen-arene products.

Although the 100 kW magnetrons operate at 92% efficiency, the remaining8% manifests itself as heat. Rejection of this heat is accomplished by awater-air chiller, sized for up to six (6) microwave generators. Withthe replacement of the inductive (transformer-based) power supply systemwith the switched-mode power supply, total heat load is reduced. In themobile version of the invention, the chiller is installed at the frontof the microwave generator trailer, forward of the nitrogen generatorsystem. In the mobile version of the invention, cooling water is pumpedfrom a water reservoir, installed under the applicator on the applicatortrailer, through the chiller system and back into the microwavegenerators in a closed-loop mode.

Power for the mobile version of the microwave reduction system, isprovided by an onboard diesel electric generator, capable of generating750 kW, which is the total load from the microwave generators totaling600 kW of microwave energy, and the ancillary items, including thenitrogen generator system, liquid scrubber system, and chiller system.All pertinent electrical parameters regarding the diesel generatoroperation are displayed on a continuously updated LCD module, located onthe front of the generator control panel. Fuel for the diesel electricgenerator is pumped from a day tank, installed under the forward sectionof the applicator on the applicator trailer.

Discussion

Without being held to one theory of operation, or one mode ofperformance, it is believed that the benefits of the invention arederived at least in part, by introducing microwave excitation of watermolecules inside the organic material by subjecting the material to highfrequency radio waves in the ultra-high frequency (UHF) band. The polarwater molecules in the material attempt to align themselves withoscillating electric field at a frequency of 915 MHz or approximatelyevery nanosecond, As the molecules cannot change their alignmentsynchronously with the changing electric field, the resistance to changemanifests itself as heat, and the moisture trapped within the materialis released as water vapor or steam. The heat conducted through thematerial and capillary action within the material converts any surfacemoisture to water vapor. This efficient release of moisture from theorganic material reduces energy costs and increases throughput. In thecase of non-polar molecules, the applied microwave energy is coupled tothe entire volume of the material, resulting in dielectric polarization.Since a phase difference occurs between the applied electric field andthe energy absorbed within the material, the losses within the materialact as a resistance, resulting in additional heat generated within thematerial. The heat generated from dipolar and dielectric heating of thematerial is sufficient to effectively cause bond dissociation,generation of free radicals and hydrogen, resulting in the volumetricreduction of the material and formation of recoverable by products.

As the invention is designed for unattended, automatic operation, with adisplay in the customer's main control room, no additional operatingpersonnel are needed. The use of this invention results in an immediateincrease in process efficiency from 20-30% with incineration, 30-40%with pyrolysis, to over 85% with high-density microwave energy operatingat 915 MHz, without any consideration for heat recovery.

However, in the case of tires, plastics, PCB's, e-waste (computerwaste), roofing shingles, shale oil and bituminous coal, a phenomenaknown as thermal runaway, occurs due to the inability of these materialsto dissipate the internal heat, caused by microwave excitation of polarand non-polar materials, sufficiently fast to their surroundings.Therefore, the increase in enthalpy is greater within the material thanin the surrounding region. The internal temperature continues toincrease at an even faster rate, and decomposition of the organicmaterial subsequently occurs. When a high power density electric fieldis applied at 915 MHz, metal particles within the material separate,leading to a higher loss factor, particularly after decompositionbegins, resulting in products of decomposition with an even higher lossfactor. Since the loss factor is directly proportional to the powerdensity and the rise in temperature, the material is subjected to evenhigher internal power dissipation. As carbon is one of the intermediateproducts of high-temperature decomposition by microwave reduction, andhas a much higher loss factor than plastics or rubber, the highertemperature leads to even greater power dissipation within the material,leading to further molecular breakdown. Hydrogen released during themolecular breakdown and the thermal runaway phenomenon produce anintense series of exothermic reactions, until equilibrium occurs. Aboveequilibrium, thermodynamic control is favored.

Raw Material Particle Sizing Aspects

The starting material for this invention, as in the case of scrap tires,is typically in a random chunk form, a diameter or thickness, whichtypically varies from ½ inch (12.7 mm)×½ inch (12.7 mm) or smaller, to amaximum which does not typically exceed 2 inches (5.08 cm). Thisinvention will also process material, which has been generated by ahammer mill, whose scrap tire material approaches 3 inches (7.62 cm) insize. The penetration depth of this material at 915 MHz is severalinches, and the material retaining sides of the belt are 4 inches (10.16cm) in height; therefore, the random raw material sizes, as provided bythe scrap tire shredders and chippers, are acceptable.

An additional desirable aspect of the raw material is that the scraptire material be subjected to a steel wire removal system. Though thisstep is not necessary for the proper operation of the invention, steelwire removal contributes to an additional 12-15% process efficiency forthe microwave reduction system, which more than offsets the cost of thesteel wire removal.

Contact Time

The material contact time of the material within the applicator isprimarily dependent on the speed of the belt, which is controlled by avariable speed motor, which in a typical application will range from 1to 8 feet per minute (0.305-2.44 meters per minute). Increasing thecontact time within the applicator will increase the types of products;i.e., gas:oil ratio and composition of the hydrocarbon vapor stream.Increasing the contact time still further will result in bond breaking,leading to decrosslinking, or depropagation or depolymerization or allthree, occurring either simultaneously or sequentially, dependent on theapplied microwave power density and applicator pressure.

Waveguide Orientation

In a preferred embodiment, the waveguides will be bifurcated andpositioned at 90° with respect to the X and Y axes. In this orientation,the microwaves will be essentially out of phase with respect to eachother. Through experimentation, it was determined that the most uniformmicrowave power density was produced using this configuration, withoutgoing to the arc-over point or the voltage breakdown point. Due to thepresence of the nitrogen or argon, higher microwave power density can beapplied to the applicator, as nitrogen and argon significantly raise thevoltage breakdown point. Further, nitrogen and argon serve as ablanketing or purge gas within the waveguide, in the event of failure ofthe pressurized fused quartz, dual window assembly.

Microwave Frequency

Historically, the frequency of 915 MHz was not originally allocated foruse in the Industrial, Scientific, and Medical (ISM) applicationsthroughout the world, and no allocation for 915 MHz applications existtoday in continental Europe. However, in the United Kingdom, 894 MHz isallocated for industrial applications, a frequency at which thisinvention is capable of operating. In North and South America, 915 MHzis allocated for unlimited use in industrial applications. Operation at915 MHz is allowable in most parts of the world with proper screeningand grounding to avoid interference with communications equipment.

Formerly, only low power magnetrons (<3 kW) were available for 2450 MHzuse, but 15-60 kW magnetrons were available for 915 MHz use. Currently,magnetron selection from 2.2-60 kW exists at 2450 MHz, while magnetronsoperating a 915 MHz are available from 10-200 kW. The preferredfrequency of operation at 915 MHz for this invention was chosenprimarily for increased penetration depth, increased power availability,increased operating efficiency, and longer operating life, resulting ina reduced number of magnetrons and lower cost per kilowatt of microwaveoutput power.

Pathogen Destruction

The invention mechanically and biologically introduces microwaveexcitation of the water molecules inside municipal solid waste (MSW),biosolids, medical waste, and non-metallic construction waste bysubjecting the material to high frequency radio waves in the ultra-highfrequency (UHF) band. The pathogens and polar water molecules in thematerial attempt to align themselves with the oscillating electric fieldat a frequency of 915 MHz or approximately every nanosecond. Thepathogens or molecules within the pathogens cannot align themselvessynchronously with the applied electric field, creating an atmosphere ofexcitation, which causes heat and explodes the pathogens structurally.

At this point of excitation, not only do the pathogens self-destruct,the attached water molecules of the pathogens and organic materialrelease the trapped moisture as water vapor. The water vapor ischanneled from the inside of the organic material to the surface andedges by capillary action; where it is drawn toward the liquid scrubber.With the scrubber operating pH of >11.5, any remaining airbornepathogens, not destroyed by the high power density electric fieldprovided by the microwave energy, cannot survive in the caustic scrubberenvironment; hence, no pathogens will be exhausted to the outsideatmosphere. This is particularly important in treatment of biosolids andmedical waste. While using this invention, all data to-date hasconfirmed a 100% pathogen kill.

Microwave excitation can further reduce the volume of the MSW,biosolids, medical waste, and non-metallic construction waste to carbon,through molecular reduction, as described previously in relation toplastics, rubber, etc. However, this is not usually required in theseindustries. Only drying, pathogen kill, and volumetric reduction are thetypical primary objectives. The result of using this invention for theabove preceding applications not only meets, but also exceeds allrequirements for Class A, Alternative 6 of 40 C F.R. Part 503specification for Process to Further Reduce Pathogens (PFRP).

The process of one preferred embodiment of this invention foresees aprocess for reducing an organic material to its constituents. Theprocess includes the steps of feeding a sample of an organic compoundinto an infeed system which contains a purge gas; transferring thesample of the organic material into at least one microwave applicatorcontaining a purge gas; and exposing the sample in the microwaveapplicator to at least two sources of microwaves which are innon-parallel alignment to each other for a period of time sufficient tovolumetrically reduce the sample of organic material to itsconstituents.

The process of a further preferred embodiment may further include thesteps of: collecting a gaseous byproduct constituent formed during thevolumetric reduction of the sample in the microwave applicator; andexposing the collected gaseous byproduct constituent to a condensor fora sufficient time to allow condensables in the gaseous byproductconstituent to form a liquid. That liquid may then be collected from thecondenser; and exposed to a filter system to remove residual water. Thenon-condensables of the gaseous byproduct constituent may be collectedfrom said condenser; and exposed to a gas-contact liquid scrubber toremove contaminants.

The solid byproduct constituents from the volumetrically reduced samplein said microwave applicator may also be collected and fed into aninfeed system which contains purge gas. The solid byproduct constituentsmay be magnetically separated to separate the carbon components from themagnetic metal components. The carbon and magnetic metal components maybe vacuum separated.

During the volumetric reduction process of some preferred embodiments,the at least two sources of microwave energy may be propagated from abifurcated waveguide assembly. That waveguide assembly may introducemicrowaves which are 90° out of phase to each other and may be betweenapproximately 915 MHz and approximately 1000 MHz, but preferablyapproximately 915 MHz. The purge gas in the infeed system may bepreferably nitrogen or argon in some preferred embodiments.

The process of some preferred embodiments may be utilized tovolumetrically reduce shredded scrap tires, wherein the scrap tires arereduced to constituents of at least hydrocarbon gas and carbon,volumetrically reduce shredded asphalt roofing shingles, wherein theshingles are reduced to constituents of at least hydrocarbon gas,carbon, and fiberglass, volumetrically reduce shredded computer waste,wherein the computer waste is reduced to constituents of at leasthydrocarbon gas, carbon, and metals, volumetrically reduce shreddedscrap rubber, wherein the scrap rubber is reduced to constituents of atleast hydrocarbon gas and carbon, volumetrically reduce PCB, PAH andHCB-laden materials, wherein the PCB, PAH and HCB-laden materials arereduced to non-carcinogenic materials suitable for standard landfilldisposal, volumetrically reduce shredded municipal solid waste (MSW),volumetrically reduce medical waste, volumetrically reduce existing rockformations of existing shale oil and reducing the shale oil to itsconstituents of hydrocarbon gas, oil and carbon, and volumetricallyreduce and desulfurizing bituminous coal, wherein the bituminous coal isreduced to constituents of at least hydrocarbon gas, oil, carbon andash.

The apparatus used in some preferred embodiments of this inventionincludes a movable chassis comprising at least one microwave generator;at least one sealed and purged microwave applicator in proximity to amaterial to be reduced and in communication with the microwave generatorvia a waveguide; the applicator having at least two sources ofmicrowaves from the microwave generator, with the microwaves being innon-parallel alignment to each other, a microwave energy absorber toabsorb any reflected microwaves, a process chiller to maintain themagnetron cooling medium within the specified operating temperaturerange, and a sealed and purged multi-shuttered or rotary airlock infeedand outfeed system to move material into and out of the applicator.

The apparatus of some preferred embodiments may also include: a processgas condenser to separate condensable and non-condensable hydrocarbonvapors; and a gas-contact liquid scrubber to remove 99.99% ofcontaminants, including hydrogen sulfide, hydrogen chloride, andhydrogen bromide.

The at least two sources of microwaves in some preferred embodiments maybe propagated from a bifurcated waveguide assembly, that may introducemicrowaves, which are 90° out of phase to each other. Those microwavesmay be between approximately 915 MHz and approximately 1000 MHz, but arepreferably 915 MHz. The magnetron cooling medium temperature may bemaintained by a process chiller, and the microwave energy absorber maybe a 3-port ferrite circulator. The apparatus may further include an RFchoke-pin trap.

The best mode for carrying out the invention has been described forpurposes of illustrating the best mode known to the applicant at thetime. The examples are illustrative only and not meant to limit theinvention, as measured by the scope and merit of the claims. Theinvention has been described with reference to preferred and alternateembodiments. Obviously, modifications and alterations will occur toothers upon the reading and understanding of the specification. It isintended to include all such modifications and alterations insofar asthey come within the scope of the appended claims or the equivalentsthereof.

1. A process for reducing an organic-containing material into lowermolecular weight gaseous hydrocarbons, liquid hydrocarbons and solidcarbon constituents, said process comprising the steps of: feeding asample of said organic-containing material into an infeed system,wherein said infeed system contains a non-flammable blanketing purgegas, said infeed system selected from the group consisting of a purgedsliding shutter assembly and a multiple chamber rotary airlock system;transferring said material into at least one microwave applicatorcontaining said purge gas in a pressurized state above local atmosphericpressure to insure that no air migrates into said microwave applicatorwhich might cause a fire or explosion hazard; exposing said material insaid microwave applicator to at least two sources of microwaves from abifurcated waveguide for a period of time sufficient to volumetricallyreduce said material into said constituents, a frequency of saidmicrowaves between approximately 894 MHz and approximately 1000 MHz andwithout an external heat source, said microwaves being in non-parallelalignment to each other, such that one waveguide entry section to eachapplicator entry point is parallel to the flow of the organic materialwhile the other is perpendicular to the flow of the organic material,and further wherein a distance from the output from the bifurcatedwaveguide which couples the microwave energy to the applicator entrypoint parallel to the flow of the organic material is physically longerthan the output feeding the perpendicular port; transporting said purgegas to pressurized quartz window assemblies at an end of each wavegudeleading into said at least one microwave applicator; monitoring saidmicrowaves by use of a directional coupler system; collecting gaseousbyproduct constituents from said volumetrically reduced sample in saidmicrowave applicator; purging an outfeed system for saidorganic-containing material with a non-flammable blanketing purge gas,said outfeed system selected from the group consisting of a purgedsliding shutter assembly and a multiple chamber rotary airlock system;removing said volumetrically reduced organic-containing material fromsaid transporting means after passage from said outfeed system; coolingsaid collected gaseous byproduct constituents for a sufficient time toallow condensables in said gaseous byproduct constituents to form aliquid; and feeding said collected gaseous byproduct constituents into agas turbine coupled to an electrical generator to provide electricity toat least an external electrical grid.
 2. The process of claim 1 whichfurther comprises the steps of: collecting said liquid from said step ofcooling; and exposing said liquid to a filter system to remove residualwater.
 3. The process of claim 1 which further comprises the steps of:collecting non-condensables in said gaseous byproduct constituents fromsaid step of cooling; and exposing said non-condensables to a scrubberto remove contaminants.
 4. The process of claim 1 which furthercomprises the steps of: collecting solid byproduct constituents fromsaid volumetrically reduced sample in said microwave applicator; feedingsaid collected solid byproduct constituents into an outfeed system,wherein said outfeed system contains purge gas; and magneticallyseparating a carbon component from a magnetic metal component withinsaid collected solid byproduct constituents.
 5. The process of claim 4which further comprises the step of: vacuum separating said carboncomponent from said magnetic metal component.
 6. (canceled)
 7. Theprocess of claim 1 wherein said bifurcated waveguide assembly introducesmicrowaves which are 90° out of phase to each other.
 8. The process ofclaim 1 wherein said purge gas is nitrogen or argon.
 9. The process ofclaim 1 wherein said frequency is approximately 915 MHz.
 10. The processof claim 1 wherein said process is utilized to volumetrically reduceshredded scrap tires, wherein said scrap tires are reduced toconstituents comprising hydrocarbon gas and carbon.
 11. The process ofclaim 1 wherein said process is utilized to volumetrically reduceshredded asphalt roofing shingles, wherein said shingles are reduced toconstituents of at least hydrocarbon gas, carbon, and fiberglass. 12.The process of claim 1 wherein said process is utilized tovolumetrically reduce shredded computer waste, wherein said computerwaste is reduced to constituents of at least hydrocarbon gas, carbon,and metals.
 13. The process of claim 1, wherein said process is utilizedto volumetrically reduce shredded scrap rubber, wherein said scraprubber is reduced to constituents of at least hydrocarbon gas andcarbon.
 14. The process of claim 1, wherein said process is a utilizedto volumetrically reduce poly-chlorinated biphenyl, poly-aromatichydrocarbon and hexachlorinated benzene-laden materials, wherein saidpoly-chlorinated biphenyl, poly-aromatic hydrocarbon and hexachlorinatedbenzene-laden materials are reduced to non-carcinogenic materialssuitable for standard landfill disposal.
 15. The process of claim 1,wherein said process is utilized to volumetrically reduce shreddedmunicipal solid waste.
 16. The process of claim 1, wherein said processis utilized to volumetrically reduce medical waste.
 17. The process ofclaim 1, wherein said process is utilized to volumetrically reduceexisting rock formations of existing shale oil and reducing said shaleoil to its constituents of hydrocarbon gas, oil and carbon.
 18. Theprocess of claim 1, wherein said process is utilized to volumetricallyreduce and desulfurize bituminous coal, wherein the bituminous coal isreduced to its constituents of at least hydrocarbon gas, oil, carbon andash.
 19. The process of claim 1, wherein said temperature is at least680° F.; said microwave energy is at least 600 kW; a weight percentratio of C₁-C₂ hydrocarbon gases to C₃-C₄ hydrocarbon gases is at leastapproximately 6.5.
 20. The process of claim 19, wherein a weight percentof n-butane is approximately 2 wt. % or less.
 21. The process of claim19, wherein a liquid hydrocarbon content has characteristics of a No. 2diesel fuel.
 22. The process of claim 20, wherein said gas compositioncomprises: ˜27% by weight methane; ˜50% by weight ethane; ˜10% by weightpropane; <1% by weight i-butane; ˜2% by weight n-butane; and a balanceof nitrogen.
 23. The process of claim 1, wherein said temperature isbelow 680° F.; said microwave energy is less than 600 kW; a weightpercent ratio of C₁-C₂ hydrocarbon gases to C₃-C₄ hydrocarbon gases isapproximately
 1. 24. The process of claim 23, wherein a weight percentof methane and ethane is approximately 75% or more.
 25. The process ofclaim 23, wherein said gas composition comprises: ˜16% by weightmethane; ˜32% by weight ethane; ˜7.5% by weight propane; ˜1% by weighti-butane; ˜32% by weight n-butane; and a balance of nitrogen.
 26. Anapparatus for reducing an organic-containing material into lowermolecular weight gaseous hydrocarbons, liquid hydrocarbons and solidcarbon constituents which comprises: at least one microwave generator;at least one sealed and purged microwave applicator, said microwaveapplicator purged with a non-flammable blanketing purge gas in proximityto a material to be reduced and in communication with said microwavegenerator via a pair of waveguides, said at least one microwaveapplicator containing said purge gas in a pressurized state above localatmospheric pressure to insure that no air migrates into said microwaveapplicator which might cause a fire or explosion hazard; said applicatorhaving at least two sources of microwaves from said microwave generator,a frequency of said microwaves is between approximately 894 MHz andapproximately 1000 MHz, said microwaves being in non-parallel bifurcatedalignment to each other from a waveguide assembly, such that onewaveguide entry section to each applicator entry point is parallel tothe flow of said material while the other is perpendicular to the flowof said organic material, each of said applicator entry points having apressurized quartz window assembly that includes two flanges separatedby a rectangular waveguide one wavelength long; said applicatorreceiving only microwave energy; a directional coupler system; atransporting means with raised sides to transport saidorganic-containing material through said at least one applicator; apurge gas generating means to provide a purge gas to said microwaveapplicator during an initial purge cycle and over the organic materialunder reduction during operation, said purge gas generating additionallyproviding said purge gas to said pressurized quartz window assembliesand to a purge assembly system; said purge assembly system positioned ateach end of said transporting means which comprises: an infeed purgeassembly; and an outfeed purge assembly; said infeed and outfeed purgeassemblies purged by said purge gas from said purge gas generatingmeans; a microwave energy absorber to absorb any reflected microwaves; amagnetron cooling means to maintain the magnetron within a specifiedoperating temperature range; a process gas cooling means to separatecondensable and non-condensable hydrocarbon vapors; a scrubber; saidapparatus comprising no means capable of supplying external heat to saidmaterial to be reduced; and a gas turbine operatively coupled to anelectrical generator to use said non-condensable hydrocarbon vapors toprovide electricity to at least an external grid.
 27. The apparatus ofclaim 26 wherein said frequency is approximately 915 MHz.
 28. Theapparatus of claim 26 wherein said magnetron cooling means is a processchiller.
 29. The apparatus of claim 26 wherein said microwave energyabsorber is a 3-port ferrite circulator.
 30. The apparatus of claim 26,which further comprises an RF choke-pin trap.
 31. The process of claim 1wherein a residence time within said at least one microwave applicatoris approximately 285 milliseconds; and a temperature within said atleast one microwave applicator is at least approximately 680° F.
 32. Theprocess of claim 1 wherein said infeed and outfeed feed systems aresliding shutter assemblies which comprise at least two sliding shutterassemblies.
 33. The process of claim 32 wherein said infeed and outfeedpurge assemblies comprise at least three sliding shutter assemblies. 34.The process of claim 33 wherein the process of purging said infeed andoutfeed shutters which comprise a top, a middle and a bottom shutter,comprising the steps of: initially applying five volumes of purge gasthrough all of said shutters venting said purge gas to atmosphere; thenopening a top slide of a top shutter to receive material with a bottomslide of said uppermost shutter closed; closing said top slide of saiduppermost shutter and purging said uppermost shutter with five volumesof purging gas; opening said bottom slide of said uppermost shutter anda top slide of said middle shutter positioned below said top shutterallowing said material to drop from said top shutter into said middleshutter; closing said bottom slide of said top shutter and said topslide of said middle shutter and purging said middle shutter with fivevolumes of purging gas; opening a bottom slide of said middle shutterand a top slide of said bottom shutter positioned below said middleshutter allowing said material to drop from said middle shutter intosaid bottom shutter; closing said bottom slide of said middle shutterand a top slide of said bottom shutter and purging said bottom shutterwith five volumes of purging gas; and opening a bottom slide of saidbottom shutter and dropping said material onto said closed meshtransporting means.
 35. The process of claim 1 wherein said processfurther comprises the step of: grinding said material after existingsaid outfeed system.
 36. The process of claim 1 wherein said step offeeding said collected gaseous byproduct constituents into a gas turbinecoupled to an electrical generator to provide electricity to at least anexternal electrical grid process further comprises the step of:simultaneously providing electricity to both a microwave generator andto said external electrical grid.
 37. A process for generatingelectricity from reducing organic-containing materials into lowermolecular weight gaseous hydrocarbons, liquid hydrocarbons and solidcarbon constituents, said process comprising the steps of: feeding asample of said organic-containing material into an infeed system,wherein said infeed system contains a non-flammable blanketing purgegas; transferring said material into at least one microwave applicatorcontaining said purge gas in a pressurized state above local atmosphericpressure to insure that no air migrates into said microwave applicatorwhich might cause a fire or explosion hazard; exposing said material insaid microwave applicator to at least two sources of microwaves from abifurcated waveguide for a period of time sufficient to volumetricallyreduce said material into said constituents, a frequency of saidmicrowaves between approximately 894 MHz and approximately 1000 MHz,said microwaves being in non-parallel alignment to each other, such thatone waveguide entry section to each applicator entry point is parallelto the flow of the organic material while the other is perpendicular tothe flow of the organic material, and further wherein a distance fromthe output from the bifurcated waveguide which couples the microwaveenergy to the applicator entry point parallel to the flow of the organicmaterial is physically longer than the output feeding the perpendicularport; monitoring said microwaves by use of a directional coupler system;collecting gaseous byproduct constituents from said volumetricallyreduced sample in said microwave applicator; purging an outfeed systemfor said organic-containing material with a non-flammable blanketingpurge gas; removing said volumetrically reduced organic-containingmaterial from said transporting means after passage from said outfeedsystem; cooling said collected gaseous byproduct constituents for asufficient time to allow condensables in said gaseous byproductconstituents to form a liquid; and feeding said collected gaseousbyproduct constituents into an internal combustion gas turbine coupledto an electrical generator to provide electricity to at least anexternal electrical grid.
 38. The process of claim 37 wherein said stepof feeding said collected gaseous byproduct constituents into saidinternal combustion gas turbine uses a gaseous byproduct compositionwhich is suitable for direct introduction into said turbine.
 39. Theprocess of claim 38 wherein said step of feeding said collected gaseousbyproduct constituents into said internal combustion gas turbine uses agaseous byproduct composition which comprises: ˜27% by weight methane;˜50% by weight ethane; ˜10% by weight propane; <1% by weight i-butane;˜2% by weight n-butane; and a balance of nitrogen.
 40. The process ofclaim 37 which further comprises: reacting said collected gaseousbyproduct constituents over a catalyst to further reduce heavierhydrocarbons.
 41. The process of claim 40 wherein said catalyst isselected from the group consisting of Ni, Pt/Mo and zeolites.
 42. Theprocess of claim 37 wherein said purge gas is selected from the groupconsisting of nitrogen and argon.
 43. The process of claim 42 whereinsaid purge gas is argon.
 44. The process of claim 37 wherein saidcondensables have characteristics of a No. 2 diesel fuel.